Skip to main content
SpringerLink
Log in

Development of analysis model for geometric error in turning processes

  • Published:
Journal of Central South University Aims and scope Submit manuscript

Abstract

A finite element model was established for analyzing the geometric errors in turning operations and a two-step analyzing process was proposed. In the first analyzing step, the cutting force and the cutting heat for the cutting conditions were obtained using the AdvantEdge. Also, the deformation of a workpiece was estimated in the second step using the ANSYS. The deformation was analyzed for a 150 mm-long workpiece at three different measuring points, such as 10, 70 and 130 mm from a reference point, and the amounts of the deformation were compared through experiments. In the results of the comparison and analysis, the values obtained from these comparison and analysis represent similar tendencies. Also, it is verified that their geometric errors increase with the increase in temperature. In addition, regarding the factors that affect the deformation of a workpiece, it can be seen that the geometric error in the lathe is about 15%, the error caused by the cutting force is about 10%, and the deformation caused by the heat is about 75%.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. MASUDA M, TORRI M. The influence of cutting force on boundary failure of cutting tool [J]. Journal of Japan Society Precision Engineering, 1987, 53(10): 1596–1601. (in Japanese)

    Article  Google Scholar 

  2. YANG S, YUAN J, NI J. Real-time cutting force induced error compensation on a turning center [J]. International Journal of Machine Tools and Manufacture, 1997, 37(11): 1597–1610.

    Article  Google Scholar 

  3. LEVY E K, TSAI C L, GROOVER M P. Analytical investigation of the effect of tool wear on the temperature variations in a metal cutting tool [J]. Trans ASME, 1976, 98(1): 251–257.

    Google Scholar 

  4. NG E G, ASPINWALL D K, BRAZIL D, MONAGHAN J. Modeling of temperature and force when orthogonally machining hardened steel [J]. International Journal of Machine Tools and Manufacture, 1999, 39(6): 885–903.

    Article  Google Scholar 

  5. KIM K W, SIN H C. Development of a thermo-viscoplastic cutting model using finite element method [J]. International Journal of Machine Tools and Manufacture, 1996, 36(3): 379–397.

    Article  Google Scholar 

  6. SHIH, ALBERT J. Finite element analysis of orthogonal metal cutting mechanics [J]. International Journal of Machine Tools and Manufacture, 1996, 36(2): 255–273.

    Article  Google Scholar 

  7. LEE M J, LEE C M. A study on the development of analysis model for prediction of relative deformation between cutting tool and workpiece [J]. Journal of Korean Society Precision Engineering, 2010, 27(4): 20–26. (in Korean)

    Google Scholar 

  8. WU H Y, LEE W B, CHEUNG C F, TO S, CHEN Y P. Computer simulation of single-point diamond turning using finite element method [J]. Journal of Material Processing Technology, 2005, 167: 549–554.

    Article  Google Scholar 

  9. TOPAL E S, COGUN C. A cutting force induced error elimination method for turning operations [J]. Journal of Material Processing Technology, 2005, 170: 192–203.

    Article  Google Scholar 

  10. BENARDOS P G, MOSIALOS S, VONSNIAKOS G C. Prediction of workpiece elastic deflections under cutting forces in turning [J]. Robotics and Computer-Integrated Manufacturing, 2006, 22: 505–514.

    Article  Google Scholar 

  11. WANG X, DA Z J, BALAJI A K, JAWAHIR I S. Performance-based predictive models for turning operations and applications: Part III. Optimum cutting conditions and selection of cutting tools [J]. Journal of Manufacturing Processes, 2007, 9(1): 61–74.

    Article  Google Scholar 

  12. KUNDRAK J, KARPUSCHEWSKI B, GYANI K, BANA V. Accuracy of hard turning [J]. Journal of Materials Processing Technology, 2008, 202(1/2/3): 328–338.

    Article  Google Scholar 

  13. WANG X, DA Z J, BALAJI A J, JAWAHIR I S. Thermal error optimization modeling and real-time compensation on a CNC turning center [J]. Journal of Material Processing Technology, 2008, 207(1/3): 172–179.

    Google Scholar 

  14. BENARDOS P G, MOSIALOS S, VOSNIAKOS G C. Prediction of workpiece elastic deflections under cutting forces in turning [J]. Robotics and Computer-Integrated Manufacturing, 2006, 22(5/6): 505–514.

    Article  Google Scholar 

  15. TZENG C J, LIN Y H, YANG Y K, JENG M C. Optimization of turning operations with multiple performance characteristics using the Taguchi method and Grey relational analysis [J]. Journal of Materials Processing Technology, 2009, 209(6): 2753–2759.

    Article  Google Scholar 

  16. TZENG Y F. Parameter design optimization of computerized numerical control turning tool steels for high dimensional precision and accuracy [J]. Materials and Design, 2006, 27(8): 665–675.

    Article  Google Scholar 

  17. KISHAWY H A, HANLUND A, BALAZINSKI M. Modelling of material side flow hard turning [J]. Annals of the CIRP, 2006, 55(1): 85–88.

    Article  Google Scholar 

  18. YAHYA I. Investigating the machinability of tool steels in turning operations [J]. Materials and Design, 2007, 28(5): 1417–1424.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Design and Manufacturing Engineering, Changwon National University, Changwon, 641-773, Korea

    Mun-jae Lee & Choon-man Lee

Authors
  1. Mun-jae Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Choon-man Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Choon-man Lee.

Additional information

Foundation item: Project(RTI04-01-03) supported by the Regional Technology Innovation Program of the Ministry of Knowledge Economy (MKE), Korea

Rights and permissions

Reprints and permissions

About this article

Cite this article

Lee, Mj., Lee, Cm. Development of analysis model for geometric error in turning processes. J. Cent. South Univ. Technol. 18, 711–717 (2011). https://doi.org/10.1007/s11771-011-0752-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11771-011-0752-0

Key words

Search

Navigation